A multi-product cogeneration system using combined coal gasification and combustion

A new system has been developed for clean and highly efficient utilization of coal. The coal is first gasified and the fuel gas is then used for industrial purposes in town gas or as a fuel for gas turbines. The char residue from the gasifier is burned in a circulating fluidized-bed combustor to generate steam for power generation, process heating, refrigeration, air conditioning, etc. The ash is used to produce construction materials. Metals such as vanadium and uranium can be extracted if the metal contents of coal are sufficiently high. An important system component is the combined gasifier–combustor. Experiments show that the system can produce gas and steam simultaneously. The gas heating value is 10–14 MJ/Nm³ and the fuel conversion is over 90%. The system has low emissions and low cost. A demonstration system has been constructed at the Yangzhong Thermal Power Plant in Jiangshu Province of China. It produces 3 500 Nm³/h of dry gas and 75 mt/h steam. The CFB boiler has been in commercial operation since April 1995. It has high efficiency, good fuel adaptability, and a high load turndown ratio.     

Fast starting fuel processor for automotive fuel cell systems

A fuel processor was constructed which incorporated two burners with direct steam generation by water injection into the burner exhaust. These burners with direct water vaporization enabled rapid fuel processor start-up for automotive fuel cell systems. The fuel processor consisted of a conventional chain of reactors: auto-thermal reformer (ATR), water gas shift (WGS) reactor and preferential oxidation (PrOx) reactor. The criticality of steam to the fuel reforming process was illustrated. By utilizing direct vaporization of water, and hydrogen for catalyst light-off, excellent start performance was obtained with a start time of 20 s to 30% power and 140 s to full power.     

Gasification of hazelnut shells in a downdraft gasifier

The potential offered by biomass to reduce greenhouse gas production is now being more widely recognised. The energy in biomass may be realised either by direct combustion use, or by upgrading into more valuable and useable products such as gas, fuel oil and higher value products for utilisation in the chemical industry or for clean power generation. Up till now, gasification work has concentrated on woody biomass but recently sources of other biomass with large energy production potential have been identified, namely hazelnut shells. Therefore, a pilot scale downdraft gasifier is used to investigate gasification potential of hazelnut shells. A full mass balance is reported including the tar production rate as well as the composition of the produced gas as a function of feed rate. Additionally, the effect of feed rate on the CV/composition of the product gas and the associated variations of gasifier zone temperatures are determined with temperatures recorded throughout the main zones of the gasifier and also at the gasifier outlet and gas cleaning zones. Pressure drops are also measured across the gasifier and gas cleaning system because the produced gas may be used in conjunction with a power production engine when it is important to have low pressure drop in the system. The quality of the product gas is found to be dependent on the smooth flow of the fuel and the uniformity of the pyrolysis, and so the difficulties, encountered during the experiments are detailed. The optimum operation of the gasifier is found to be between 1.44 and 1.47 N m³/kg of air fuel ratios at the values of 4.06 and 4.48 kg/h of wet feed rate which produces the producer gas with a good GCV of about 5 MJ/m³ at a volumetric flow of 8–9 N m³/h product gas. It was concluded that hazelnut shells could be easily gasified in a downdraft gasifier to produce good quality gas with minimum polluting by-products. It is suggested that, in view of ease of operation, small-scale gasifiers can make an important contribution to the economy of rural areas where the residues of nuts are abundant. It is also suggested that gasification of shell waste products is a clean alternative to fossil fuels and the product gas can be directly used in internal gas combustion engines, thus warranting further investment/encouragement by authorities to exploit this valuable resource.     

Cogeneration potential in the Columbian palm oil industry: Three case studies

The palm oil mills are characterized by the availability of considerable amounts of by-products of high-energy value such as empty fruit bunches (EFB), fibers, shells and liquid effluents with high content of organics called palm oil mill effluent (POME). A palm oil mill produces residues equivalent to almost three times the amount of oil produced by biomass, showing a huge potential for increasing the power efficiency of the plants and installed power, mainly by the use of by-products in cogeneration plants with high steam parameters and by reducing steam consumption in process. The objective of this paper is to present the results of the study about the cogeneration potential for three representative palm oil mills located in two important palm oil producing regions in Colombia (South-America), fifth palm oil producers of the world. The sizing of the cogeneration system was made assuming it operation during the greatest possible number of hours throughout the year (based on the seasonal availability of fruit) considering parameters for the steam at 2 MPa and 350 °C, using a condensing-extraction turbine. The balance of mass and energy was made by using the Gate Cycle Enter Software, version 5.51, to estimate the potential of electricity generation. The results showed that for fresh fruit bunch (FFB) processing capacities between 18 and 60 t FFB h⁻¹, it is possible to have surplus power ranging between 1 and 7 MW, if the plants are self-sufficient in electric energy and steam for process. With an average Capacity Factor (approximately 0.4), it is possible to expect a generation index of 75 and 160 kWh t⁻¹ FFB when the processing plant is operating or shutdown, respectively, 3 or 4 times better than when a traditional system with a back-pressure steam turbines is used. This analysis used up to 60% of EFB produced in plant as fuel, considering its value as fertilizer for the palm crop. Several economic conditions were considered to estimate the economic and technical feasibility of cogeneration systems in palm oil mill for Colombian palm oil sector.     

A 75-kW methanol reforming fuel cell system

A 75-kW methanol reforming fuel cell system, which consists of a fuel cell system and a methanol auto-thermal reforming fuel processor has been developed at Dalian Institute of Chemical Physics, Chinese Academy of Sciences (CAS). The core of the fuel cell system is a group of CO tolerant PEMFC stacks with a double layer composite structured anode. The fuel cell stacks show good CO tolerance even though 140 ppm CO was present in the reformate stream during transients. The auto-thermal reforming (ATR) fuel cell processor could adiabatically produce a suitable reformate without external energy consumption. The output of hydrogen-rich reformate was approximately 120 N m³ h⁻¹ with a H₂ content near 53% and the CO concentrations generally were under 30 ppm. The fuel cell system was integrated with the methanol reforming fuel processor and the peak power output of the fuel cell system exceeded 75 kW in testing. The hydrogen utilization approached 70% in the fuel cell system.     

Emission characteristics and axial flame temperature distribution of producer gas fired premixed burner

This paper presents the emission characteristics and axial flame temperature distribution of producer gas fired premixed burner. The producer gas fired premixed burner of 150 kW capacity was tested on open core throat less down draft gasifier system in the present study. A stable and uniform flame was observed with this burner. An instrumented test set up was developed to evaluate the performance of the burner. The conventional bluff body having blockage ratio of 0.65 was used for flame stabilization. With respect to maximum flame temperature, minimum pressure drop and minimum emissions, a swirl angle of 60° seems to be optimal. The experimental results also showed that the NO_x emissions are inversely proportional to swirl angle and CO emissions are independent of swirl angle. The minimum emission levels of CO and NO_x are observed to be 0.167% and 384 ppm respectively at the swirl angle of 45–60°. The experimental results showed that the maximum axial flame temperature distribution was achieved at A/F ratio of 1.0. The adiabatic flame temperature of 1653 °C was calculated theoretically at A/F ratio of 1.0. Experimental results are in tune with theoretical results. It was also concluded that the CO and UHC emissions decreases with increasing A/F ratio while NO_x emissions decreases on either side of A/F ratio of 1.0.     

A 28-W portable direct borohydride–hydrogen peroxide fuel-cell stack

A 28-W direct borohydride–hydrogen peroxide fuel-cell stack operating at 25 °C is reported for contemporary portable applications. The fuel cell operates with the peak power-density of ca. 50 mW cm⁻² at 1 V. This performance is superior to the anticipated power-density of 9 mW cm⁻² for a methanol–hydrogen peroxide fuel cell. Taking the fuel efficiency of the sodium borohydride–hydrogen peroxide fuel cell as 24.5%, its specific energy is ca. 2 kWh kg⁻¹. High power-densities can be achieved in the sodium borohydride system because of its ability to provide a high concentration of reactants to the fuel cell.     

Combustion characteristics of a 4-stroke CI engine operated on Honge oil,Neem and Rice Bran oils when directly injected and dual fuelled with producer gas induction

Energy is an essential requirement for economic and social development of any country. Sky rocketing of petroleum fuel costs in present day has led to growing interest in alternative fuels like vegetable oils, alcoholic fuels, CNG, LPG, Producer gas, biogas in order to provide a suitable substitute to diesel for a compression ignition (CI) engine. The vegetable oils present a very promising alternative fuel to diesel oil since they are renewable, biodegradable and clean burning fuel having similar properties as that of diesel. They offer almost same power output with slightly lower thermal efficiency due to their lower energy content compared to diesel. Utilization of producer gas in CI engine on dual fuel mode provides an effective approach towards conservation of diesel fuel. Gasification involves conversion of solid biomass into combustible gases which completes combustion in a CI engines. Hence the producer gas can act as promising alternative fuel and it has high octane number (100–105) and calorific value (5–6 MJ/Nm³). Because of its simpler structure with low carbon content results in substantial reduction of exhaust emission. Downdraft moving bed gasifier coupled with compression ignition engine are a good choice for moderate quantities of available mass up to 500 kW of electrical power. Hence bio-derived gas and vegetable liquids appear more attractive in view of their friendly environmental nature. Experiments have been conducted on a single cylinder, four-stroke, direct injection, water-cooled CI engine operated in single fuel mode using Honge, Neem and Rice Bran oils. In dual fuel mode combinations of Producer gas and three oils were used at different injection timings and injection pressures.Dual fuel mode of operation resulted in poor performance at all the loads when compared with single fuel mode at all injection timings tested. However, the brake thermal efficiency is improved marginally when the injection timing was advanced. Decreased smoke, NO_x emissions and increased CO emissions were observed for dual fuel mode for all the fuel combinations compared to single fuel operation.     

Environmental aspects of ethanol derived from no-tilled corn grain: nonrenewable energy consumption and greenhouse gas emissions

Nonrenewable energy consumption and greenhouse gas (GHG) emissions associated with ethanol (a liquid fuel) derived from corn grain produced in selected counties in Illinois, Indiana, Iowa, Michigan, Minnesota, Ohio, and Wisconsin are presented. Corn is cultivated under no-tillage practice (without plowing). The system boundaries include corn production, ethanol production, and the end use of ethanol as a fuel in a midsize passenger car. The environmental burdens in multi-output biorefinery processes (e.g., corn dry milling and wet milling) are allocated to the ethanol product and its various coproducts by the system expansion allocation approach.The nonrenewable energy requirement for producing 1 kg of ethanol is approximately 13.4–21.5 MJ (based on lower heating value), depending on corn milling technologies employed. Thus, the net energy value of ethanol is positive; the energy consumed in ethanol production is less than the energy content of the ethanol (26.8 MJ kg⁻¹).In the GHG emissions analysis, nitrous oxide (N₂O) emissions from soil and soil organic carbon levels under corn cultivation in each county are estimated by the DAYCENT model. Carbon sequestration rates range from 377 to 681 kg C ha⁻¹ year⁻¹ and N₂O emissions from soil are 0.5–2.8 kg N ha⁻¹ year⁻¹ under no-till conditions. The GHG emissions assigned to 1 kg of ethanol are 260–922 g CO₂ eq. under no-tillage. Using ethanol (E85) fuel in a midsize passenger vehicle can reduce GHG emissions by 41–61% km⁻¹ driven, compared to gasoline-fueled vehicles. Using ethanol as a vehicle fuel, therefore, has the potential to reduce nonrenewable energy consumption and GHG emissions.     

Feasibility study of Jatropha seed husk as an open core gasifier feedstock

This paper presents the results of investigation carried out in studying the fuel properties of Jatropha seed husk and its gasification feasibility for open core down draft gasifier. Jatropha seed husk was converted to producer gas in an open core down draft gasifier whose performance was evaluated in terms of fuel consumption rate, calorific value of producer gas and gasification efficiency at different gas flow rates. It was found that producer gas calorific value and concentration of CO, along with gasification efficiency, in general, increased with the increase in gas flow rate. The maximum gasification efficiency was found to be 68.31% at a gas flow rate of 5.5 m³ h⁻¹ and specific gasification rate of 270 kg h⁻¹ m⁻². Studies revealed that Jatropha seed husk could successfully be used as feedstock for open core down draft gasifier.     

Optimization of ethanol production from sweet sorghum (Sorghum bicolor) juice using response surface methodology

Sweet sorghum juice was fermented into ethanol using Saccharomyces cerevisiae (ATCC 24858). Factorial experimental design, regression analysis and response surface method were used to analyze the effects of the process parameters including juice solid concentration from 6.5 to 26% (by mass), yeast load from 0.5 g L⁻¹ to 2 g L⁻¹ and fermentation temperature from 30 °C to 40 °C on the ethanol yield, final ethanol concentration and fermentation kinetics. The fermentation temperature, which had no significant effect on the ethanol yield and final ethanol concentration, could be set at 35 °C to achieve the maximum fermentation rate. The yeast load, which had no significant effect on the final ethanol concentration and fermentation rate, could be set at 1 g L⁻¹ to achieve the maximum ethanol yield. The juice solid concentration had significant inverse effects on the ethanol yield and final ethanol concentration but a slight effect on the fermentation rate. The raw juice at a solid concentration of 13% (by mass) could be directly used during fermentation. At the fermentation temperature of 35 °C, yeast solid concentration of 1 g L⁻¹ and juice solid concentration of 13%, the predicted ethanol yield was 101.1% and the predicted final ethanol concentration was 49.48 g L⁻¹ after 72 h fermentation. Under this fermentation condition, the modified Gompertz's equation could be used to predict the fermentation kinetics. The predicted maximum ethanol generation rate was 2.37 g L⁻¹ h⁻¹.     

Operation of PEM fuel cells at 120–150 °C to improve CO tolerance

Sulfonic acid modified perfluorocarbon polymer proton exchange membrane (PEM) fuel cells operated at elevated temperatures (120–150 °C) can greatly alleviate CO poisoning on anode catalysts. However, fuel cells with these PEMs operated at elevated temperature and atmospheric pressure typically experience low relative humidity (RH) and thus have increased membrane and electrode resistance. To operate PEM fuel cells at elevated temperature and high RH, work is needed to pressurize the anode and cathode reactant gases, thereby decreasing the efficiency of the PEM fuel cell system. A liquid-fed hydrocarbon-fuel processor can produce reformed gas at high pressure and high relative humidity without gas compression. If the anode is fed with this high-pressure, high-relative humidity stream, the water in the anode compartment will transport through the membrane and into the ambient pressure cathode structure, decreasing the cell resistance. This work studied the effect of anode pressurization on the cell resistance and performance using an ambient pressure cathode. The results show that high RH from anode pressurization at both 120 and 150 °C can decrease the membrane resistance and therefore increase the cell voltage. A cell running at 150 °C obtains a cell voltage of 0.43 V at 400 mA cm⁻² even with 1% CO in H₂. The results presented here provide a concept for the application of a coupled steam reformer and PEM fuel cell system that can operate at 150 °C with reformate and an atmospheric air cathode.     

Investigation of hydrogen production from boron compounds for pem fuel cells

This paper presents a comprehensive study of hydrogen production from sodium borohydride (NaBH₄), which is synthesized from sodium tetraborate (Na₂B₄O₇) decomposition, for proton exchange membrane (PEM) fuel cells. For this purpose, Na₂B₄O₇ decomposition reaction at 450–500 °C under hydrogen atmosphere and NaBH₄ decomposition reaction at 25–40 °C under atmospheric pressure are selected as a common temperature range in practice, and the inlet molar quantities of Na₂B₄O₇ are chosen from 1 to 6 mol with 0.5 mol interval as well. In order to form NaBH₄ solution with 7.5 wt.% NaBH₄, 1 wt.% NaOH, 91.5 wt.% H₂O, the molar quantities of NaBH₄ are determined. For a PEM fuel cell operation, the required hydrogen production rates are estimated depending on 60, 65, 70 and 75 g of catalyst used in the NaBH₄ solution at 25, 32.5 and 40 °C, respectively. It is concluded that the highest rate of hydrogen production per unit area from NaBH₄ solution at 40 °C is found to be 3.834 × 10⁻⁵ g H₂ s⁻¹ cm⁻² for 75 g catalyst. Utilizing 80% of this hydrogen production, the maximum amounts of power generation from a PEM fuel cell per unit area at 80 °C under 5 atm are estimated as 1.121 W cm⁻² for 0.016 cm by utilizing hydrogen from 75 g catalyst assisted NaBH₄ solution at 40 °C.     

Optimum hydrogen generation capacity and current density of the PEM-type water electrolyzer operated only during the off-peak period of electricity demand

A requirement for widespread adoption of fuel cell vehicles in the transportation sector will be ready availability of pure hydrogen at prices that result in operating costs comparable to, or less than, that of gasoline internal combustion engine vehicles. The existing electrical power grid could be used as the backbone of the hydrogen infrastructure system in combination with water electrolyzers. A water electrolyzer can contribute to the load leveling by changing operational current density in accordance with the change of electricity demand. The optimum hydrogen generation capacity and current density of the polymer electrolyte membrane (PEM)-type water electrolyzer operated only during the off-peak period of electricity demand in respect of both the shortest time required for start and the higher efficiency of water electrolysis are obtained as 500 Nm³ h⁻¹ and 30 kA m⁻², respectively. This PEM-type water electrolyzer could be used in the hydrogen refueling stations and energy storage systems constructed around hydrogen.     

Electrochemical lithium insertion in TiO2 with the ramsdellite structure

The electrochemical insertion of lithium in the ramsdellite polymorph of titanium dioxide, TiO₂ (R), is studied by electrochemical methods. At room temperature the maximal Li uptake under constant current densities of 0.1, 0.5 and 1.0 mA cm⁻² is 0.85, 0.8 and 0.7 Li/Ti, respectively. Between 2.3 and 1.3 V versus lithium, the specific capacity achieved is as high as 285 A h kg⁻¹ at 0.5 mA cm⁻². This corresponds to 85% of the maximum theoretical capacity (336 A h kg⁻¹), which may be reached by incorporation of one lithium per titanium under equilibrium conditions.     

Feasibility study of cashew nut shells as an open core gasifier feedstock

This paper present the results of investigation carried out in studying the fuel properties of cashew nut shell and its gasification feasibility for open core down draft gasifier. Cashew nut shell was converted to producer gas in an open core down draft gasifier whose performance was evaluated in terms of fuel consumption rate, calorific value of producer gas and gasification efficiency at different gas flow rates. It was found that producer gas calorific value and volumetric percentage of its combustible constituents, along with gasification efficiency, in general, increased with the increase in gas flow rate. The maximum gasification efficiency was found to be 70% at a gas flow rate of 130 m³ h⁻¹ and specific gasification rate of 167 kg h⁻¹m⁻². Studies revealed that cashew nut shells could successfully be used as feedstock for open core down draft gasifier.     

The role of ambient conditions on the performance of a planar,air-breathing hydrogen PEM fuel cell

This paper presents experimental data on the effects of varying ambient temperature (10–40 °C) and relative humidity (20–80%) on the operation of a free-breathing fuel cell operated on dry-hydrogen in dead ended mode. We visualize the natural convection plume around the cathode using shadowgraphy, measure the gas diffusion layer (GDL) surface temperature and accumulation of water at the cathode, as well as obtain polarization curves and impedance spectra. The average free-convection air speed was 9.1 cm s⁻¹ and 11.2 cm s⁻¹ in horizontal and vertical cell orientations, respectively. We identified three regions of operation characterized by increasing current density: partial membrane hydration, full membrane hydration with GDL flooding, and membrane dry-out. The membrane transitions from the fully hydrated state to a dry out regime at a GDL temperature of approximately 60 °C, irrespective of the ambient temperature and humidity conditions. The cell exhibits strong hysteresis and the dry membrane regime cannot be captured by a sweeping polarization scan without complete removal of accumulated water after each measurement point. Maximum power density of 356 mW cm⁻² was measured at an ambient temperature of 20 °C and relative humidity of 40%.     

Development of a miniaturized polymer electrolyte membrane fuel cell with silicon separators

The fabrication process and electrochemical characterization of a miniaturized PEM fuel cell with silicon separators were investigated. Silicon separators were fabricated with silicon fabrication technologies such as by photolithography, anisotropic wet etching, anodic bonding and physical vapor deposition (PVD). A 400 μm × 230 μm flow channel was made with KOH wet etching on the front side of a silicon separator, and then a 550 nm gold current collector and 350 nm TiN_x thin film heater were respectively formed on the front side and the opposite side by PVD. Two separators were assembled with the membrane electrode assembly (MEA) having a 4 cm² active area for the single cell. With pure hydrogen and oxygen under atmospheric pressure without humidification, the performance of the single fuel cell was measured. A single cell operation led to generation of 203 mW cm⁻² at 0.6 V at room temperature, which corresponded to 360 mW cm⁻³ in terms of volumetric fuel cell power density, with 20 ccm of gas flow rate of hydrogen and oxygen at the inlet.     

Life cycle assessment of a Brassica carinata bioenergy cropping system in southern Europe

The energetic and environmental performance of production and distribution of the Brassica carinata biomass crop in Soria (Spain) is analysed using life cycle assessment (LCA) methodology in order to demonstrate the major potential that the crop has in southern Europe as a lignocellulosic fuel for use as a renewable energy source.The Life Cycle Impact Assessment (LCIA) including midpoint impact analysis that was performed shows that the use of fertilizers is the action with the highest impact in six of the 10 environmental categories considered, representing between 51% and 68% of the impact in these categories.The second most important impact is produced when the diesel is used in tractors and transport vehicles which represents between 48% and 77%. The contribution of the B. carinata cropping system to the global warming category is 12.7 g CO₂ eq. MJ⁻¹ biomass produced. Assuming a preliminary estimation of the B. carinata capacity of translocated CO₂ (631 kg CO₂ ha⁻¹) from below-ground biomass into the soil, the emissions are reduced by up to 5.2 g CO₂ eq. MJ⁻¹.The production and transport are as far as a thermoelectric plant of the B. carinata biomass used as a solid fuel consumes 0.12 MJ of primary energy per 1 MJ of biomass energy stored. In comparison with other fossil fuels such as natural gas, it reduces primary energy consumption by 33.2% and greenhouse gas emission from 33.1% to 71.2% depending on whether the capacity of translocated CO₂ is considered or not.The results of the analysis support the assertion that B. carinata crops are viable from an energy balance and environmental perspective for producing lignocellulosic solid fuel destined for the production of energy in southern Europe. Furthermore, the performance of the crop could be improved, thus increasing the energy and environmental benefits.     

A polymer electrolyte fuel cell life test: 3 years of continuous operation

Implementation of polymer electrolyte fuel cells (PEMFCs) for stationary power applications requires the demonstration of reliable fuel cell stack life. One of the most critical components in the stack and that most likely to ultimately dictate stack life is the membrane electrode assembly (MEA). This publication reports the results of a 26,300 h single cell life test operated with a commercial MEA at conditions relevant to stationary fuel cell applications. In this experiment, the ultimate MEA life was dictated by failure of the membrane. In addition, the performance degradation rate of the cell was determined to be between 4 and 6 μV h⁻¹, at the operating current density of 800 mA cm⁻². AC impedance analysis and DC electrochemical tests (cyclic voltammetry and polarization curves) were performed as diagnostics during and on completion the test, to understand materials changes occurring during the test. Post mortem analyses of the fuel cell components were also performed.